Storage container and method of forming same

ABSTRACT

A storage container is provided, having a first container portion and a second container portion. The first container portion is approximately 24 feet in length, having a first front portion. The second container portion is approximately 16 feet in length, having a second front portion. The first and second front portions are coupled to form a storage container approximately 40 feet in length and having a opening extending approximately 40 feet through the storage container. A first panel of the first front portion is mounted to an inside surface of the storage container and a second panel of the second front portion is mounted to an inside surface of the storage container.

BACKGROUND OF THE INVENTION

The present invention relates to the field of storage containers, methods of formation of storage containers, and use of storage containers to ship goods.

Storage containers are used to transport goods across oceans on large ships, and across land on truck beds. In order to ship containers across seas, the containers must conform to the Convention of Safe Containers, which determines the dimensions and load capacities of different containers. Containers of predetermined dimensions are generally loaded into the cell of a ship and stacked one upon another for transport. For example, it is known to provide containers measuring 20 feet in total length and 40 feet in total length for loading into a cell of a ship.

Storage containers are also used to store items at construction sites, homes, and elsewhere, and can be used accordingly upon completion of shipping on ships. Different sizes of storage containers may be desired according to the various applications for which the storage container may be used. For example, containers measuring 10, 16, or 24 feet in length may be desired according to various applications.

It is known to join two containers measuring 10 feet each in length to form the container measuring 20 feet in total length. The container measuring 20 feet in total length may be used during shipping and then separated into two containers measuring 10 feet in length. In this manner, the shipping of cargo using containers can proceed according to the length requirement, and the later use of storage containers can proceed according to the length desired for the particular application.

For a standard 40 foot container, it is known to provide a tunnel extending along a bottom surface of the container. The tunnel allows the 40 foot container to rest on the bed of a chassis, where it can be used to ship cargo over land.

SUMMARY

One embodiment of the present invention includes a storage container having a first container portion approximately 24 feet in length and having a first front portion, and a second container portion approximately 16 feet in length and having a second front portion. The first and second front portions are coupled to form a cargo container approximately 40 feet in length and having an opening extending approximately 40 feet through the storage container. A first panel to cover the first end portion is mounted to the storage container and a second panel to cover the second end portion is mounted to the storage container.

In another embodiment, the first and second front portions are coupled by a joining panel.

In another embodiment, a storage container includes forklift pockets extending laterally near a bottom surface of the storage container. The bottom surface also includes a tunnel extending along a portion of a length of the storage container from a first end of the storage container. The tunnel includes two spaced apart side members extending perpendicular to the fork pockets. At least one opening is provided in at least one of the two side members of the tunnel at an intersection of at least one forklift pocket and the tunnel, the opening configured to allow passage of a fork of a forklift through the forklift pocket into the tunnel.

In another embodiment of the invention, a method of shipping a container includes fixing a first container and a second container together, the first container measuring approximately 24 feet in length and the second container measuring approximately 16 feet in length, to form a completed container measuring approximately 40 feet in length. Front panels are mounted to the first and second containers to permit a through opening of approximately 40 feet in length to extend through the completed container. The completed container is then loaded, shipped and unloaded.

In another embodiment, the method of shipping the container further includes renting the completed container to a shipper for shipping a load and/or selling the first and second containers to one or more parties, and delivering the first and second containers to the one or more parties after shipping the completed container.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a side view of a completed storage container according to an exemplary embodiment of the present invention;

FIG. 2 is a side perspective view of the container of FIG. 1;

FIG. 3 is a bottom perspective view of the container of FIG. 1;

FIG. 4 is a cross-sectional view according to the line 4-4 of FIG. 1;

FIGS. 5A to 5C are a front view, a cross-sectional view according to the line 5B-5B of FIG. 5A, and a cross-sectional view according to the line 5C-5C of FIG. 5A, respectively, of a storage container according to an exemplary embodiment of the present invention;

FIGS. 6A to 6C are a front view, a cross-sectional view according to the line 6B-6B of FIG. 6A, and a cross-sectional view according to the line 6C-6C of FIG. 6A, respectively, of the container of FIGS. 5A to 5C;

FIGS. 7A and 7B are cross-sectional views of a joining panel with and without containers attached thereto, respectively, according to an exemplary embodiment of the present invention;

FIG. 8 is a cross-sectional view according to the line 8-8 of FIG. 1; and

FIG. 9 is a flow chart of a process for use of a storage container according to aspects of the present invention.

DETAILED DESCRIPTION

With reference to FIG. 1, a completed storage container 10 for the storage and transport of goods includes a first container 12 and a second container 14. The first container 12 and the second container 14 are attached to one another, as described below, to form the completed container 10. The completed container is 40 feet in length according to a dimension L, which is a length used to form shipping containers.

The completed container 10 is generally used to ship cargo in a ship across seas. Upon arrival at a shipping destination, the completed container 10 is capable of being separated into the first and second containers 12, 14, as described below. Upon separation from one another, the first and second containers 12, 14 may be used for separate applications. The completed container is generally made of steel of different varieties, but may be made of any suitable material. Anti-corrosive steel or an equivalent is often used to form the completed container 10.

The completed container 10 includes four corner posts 16 (two not seen) extending vertically according to the dimension H along junctions of various panels used to form the completed container 10. The corner posts 16 are formed from rolled high tensile steel, for example. Top side rails 15 and bottom side rails 17 extend horizontally according to the dimension L along junctions of the panels. Corner fittings 18 are located at the top and bottom of the corner posts 16. The corner fittings 18 are formed of casted weldable steel, for example. The corner posts 16 are designed to bear the load of the containers, particularly as the containers are stacked one on top of another in the ship silo or on a loading dock, as is known in the art. The corner posts 16 also provide structural support for lifters which grasp the completed container at the corner fittings 18 and corner posts 16 to stack and/or transport individual completed containers at a loading dock or on a ship, as known in the art. The corner fittings include openings 19 for engagement by the lifters. The corner posts 16 and the rails 15, 17 are welded into the corner fittings 18.

The completed container 10 is formed with panels and doors. Side panels 21 extend between the corner posts 16 along the length L of the completed container 10. The side panels 21 are corrugated in order to provide structural rigidity to the completed container 10. A top panel (not shown) extends along a top surface of the completed container 10 between the top rails 15. A first end 23 and a second end 25 of the completed container 10 each include doors, described in more detail below. The completed container also includes a bottom (not shown) extending between the bottom rails 17. The side panels 21, top panel, bottom and doors located at the first and second ends 23, 25 together define an inside area of the completed container.

The first container 12 is 24 feet in length according to a dimension L1, and can be separated from the second container 14, as described below. The length L1 of the separated first container 12 is beneficial for use on the bed of transport trucks, as well as for storage applications involving pipe, which often measures approximately 24 feet. The second container 14 is approximately 16 feet in length according to a dimension L2. The length L2 of the separated second container 14 is particularly beneficial for use in storage applications where a 10 foot container is too small and a 20 foot container is too long. The first or second container 12 or 14 may also be placed on flat rail cars and secured by twistlocks at the bottom corner fittings of the first or second container. The first and second containers may be used in a variety of applications, and may remain permanently attached to one another, according to the application for which the completed container 10 is to be used. It will also be appreciated that other length containers may be used to form a 40 foot container, such as a 25 foot first container and a 15 foot second container.

The first and second containers 12, 14 are joined at a junction point 26 of the completed container 10. At the junction point 26, the first and second containers each include a front end 27. The front ends 27 of the first and second containers 12, 14 include corner posts 28, similar to the corner posts 16 in form and function, and corner fittings 29, similar to the corner fittings 18. The front ends 27 are joined together by a joining apparatus 31, as described below, to form the completed container 10. When detached from each other, the front ends 27 of the first and second containers 12, 14 may be provided with front panels (not shown) attached thereto, as described below. With the front panels attached to the front ends 27, the first and second containers 12, 14 are used for their respective applications, as described above.

The first and second containers 12, 14 are lifted using forklift pockets 20 located along a lower edge of the containers, near a surface on which the containers rest. The forklift pockets, explained in greater detail below, extend laterally along a bottom of the containers 12, 14, and are spaced along the lengths L1 and L2 to allow for engagement with a fork lift, which lifts the first or second container as known in the art.

With reference to FIG. 2, the first container 12 includes a door 30 at the first end 23 of the completed container 10. The second container 14 may also be provided with a door (not shown) at the second end 25 of the completed container. When used, the second door is typically tack welded shut for customs purposes. The door 30 of the first container 12 provides access to an inside area of the container, and through it, items may be placed in the completed container 10. At the first end, a tunnel 32 extends along a bottom surface 34 of the first container 12, toward the second container 14.

With reference to FIG. 3, the tunnel 32, sometimes called a gooseneck tunnel, extends along a portion of the first container 12. A common application of the container 10 involves use with transport trucks. The tunnel 32 of the container 10 is configured to interact with a bed of a transport truck. The tunnel 32 is defined by a first side rail 36 and a second side rail 38 running approximately parallel to one another, a tunnel plate 40 extending between the first side rail and second side rail, and a back rail 42 extending between the first and second rails 36, 38. One of the forklift pockets 20 of the first container 12 extends laterally across the first container adjacent to the bottom surface 34, and intersects with the tunnel 32.

With reference to FIGS. 3 and 4, the forklift pocket 20 is defined by a bottom plate 44, a top plate 46, and fork lift pocket cross members 48. Additional cross members 50 are placed laterally along the bottom surface 34 of the first container 12 at predetermined intervals to provide structural support to the container and to provide an offset between the surface on which the container rests and the inside area of the container, thus allowing container contents to remain dry should moisture collect around the bottom surface 34 of the container. The cross members 48, 50 are welded into the first and second side rail 36, 38 in the area of the tunnel 32. Toward outer edges of the bottom surface 34, the cross members are welded to the bottom side rails 17. In the area of the forklift pockets, openings 54 are placed in the bottom side rails 17 through which prongs of a forklift may pass into the forklift pocket. Openings 56 are also placed in the first and second rails 36, 38 of the tunnel 32, allowing passage of the forklift prongs into the tunnel 32. The openings 56 in the first and second rails 36, 38 allow the forklift to lift the container. For example, a container having openings in the side rails 36, 38 of the tunnel 32 allows a forklift to lift the container at the top plate 46 of the forklift pocket 20 and at bearing members 49 attached to the tunnel plate 40, whereas a container not having the openings 56 allows a fork lift to lift only along the top plate 46 of the forklift pocket as the side rails 36, 38 of the tunnel 32 create a barrier through which the forklift cannot pass.

A container flooring 58 extends between the bottom side rails 17. The container flooring is formed of hardwood plywood, for example. In the area of the tunnel 32, the container flooring is interrupted by the tunnel plate 40. The cross members 48, 50 are secured to a bottom surface of the container flooring 58 by fasteners or other known means. The top plate 46 extends between the cross members 48 and is secured to the bottom surface of the container flooring 58. The top plate 46 is positioned vertically offset to the tunnel plate 40 and the bottom side rails 17 such that an upper surface of the container flooring 58 co-extends with an upper surface of the tunnel plate 40, providing an even surface for the storage of goods within an inside area of the container.

The bottom surface 34 of the first container 12 is partially defined by the container flooring 58 in areas outside the forklift pocket (see FIG. 3). Cross members 48, 50 also partially define the bottom surface 34 (see FIG. 3), as do the bottom side rails 17 (see FIG. 2), the tunnel plate 40 (see FIG. 4), and the bottom plate 44 of the forklift pocket 20 (see FIG. 4).

With reference to FIGS. 1 and 5A to SC, the front end 27 of the container 12 or 14 includes a top front rail 78, two vertically extending corner posts 28, and a bottom front rail 82. The rails 78, 82 and the posts 28 are joined by the corner fittings 29, into which the top side rails 15 and bottom side rails 17 are also joined (see FIG. 1). An opening into an inner area of the container in the front end 27 is defined by a top lip 90 of the top front rail 78, two side lips 92 of the corner posts 80, and a bottom lip 94 of the bottom front rail 82. The lips 90, 92, and 94 are used to secure a front panel of the container 12 or 14, as described below.

The top front rail 78 includes an upwardly facing surface 96 on the top lip 90. The corner posts 80 include end surfaces 98 on the side lips 92. The bottom front rail 82 includes an outwardly facing surface 100. The surfaces 96, 98, and 100 are used to secure a joining panel, described below, to the container 12 or 14. The opening of one of the first and second containers 12, 14 is aligned with a similar opening in the other of the first and second containers 12, 14, and the front ends 27 of the respective containers are joined to form the completed container 10 (see FIG. 1), as described below.

With reference to FIGS. 6A to 6C, the first or second container 12 or 14 are shown with a panel 102 attached to the front end 27 thereof. The front panels are not attached during loading or shipment, but are attached after the containers arrive at the destination and are removed from the ship. The front panel 102 is corrugated in shape, and matches the corrugation of the side panels 21 of the first and second containers 12, 14 (see FIG. 1). The front panel 102 includes a top end surface 104, an inner surface 106, and bottom end surface 108.

According to an exemplary method of the invention, the front panels 102 of the first and second containers 12, 14 may be mounted to the inside area of one or both of the containers 12, 14 for transport during shipping of the completed container 10 (see FIG. 1). The front panels 102 are secured to the side panels 21 in the inside area of the container 12 or 14. The corrugated profile of the front panels 102 matches that of the side panels 21 such that the front panels 102 nest into the side panels 21, maximizing the inside area in which cargo or other storage items can be placed when the front panels 102 are secured to the side panels 21. The front panels 102 may be tack welded onto the side panels 21. Alternatively, the front panels 102 may include openings for engagement with a hook or a lashing ring, the hook or lashing ring being mounted on the side panel 21.

Once the container arrives at its destination and is unloaded, the front panels can be attached to the front ends 27 of the first and second containers. The top end surface 104 is secured to the top lip 90 of the top front rail 78 as shown in FIG. 6B. The inner surface 106 of the panel 102 is secured to the second lips 92 as shown in FIG. 6C. The bottom end surface 108 is secured to the bottom lip 94 of the bottom front rail 82. The front panel 102 may be secured to the container 12 or 14 along the lips 90, 92, and 94 by welding, for example.

The front ends 27 of the first and second containers 12 and 14 are placed adjacent to one another in order to form the completed container 10 (see FIG. 1). To form the completed container, the front panels 102 are not attached to the front ends 27, as shown in FIGS. 5A to 5C. Rather, the panels 102 may be mounted to the side panels 21 either before or after the formation of the completed container, as described above.

With reference to FIGS. 7A to 8, the joining apparatus 31 (see FIG. 1) for joining the first and second containers 12, 14 includes a joining panel 110 used to place inside areas of the first and second containers 12, 14 in communication with one another. The joining panel 110 includes a top joining panel 112, two side joining panels 114, and a bottom joining panel 116. The joining panel 110 is rectangular and includes an opening 118 extending therethrough. The top joining panel 112 includes a downwardly facing surface 120 which is secured to the upwardly facing surfaces 96 of the top front rails 78. The side joining panels 114 include an outwardly facing surface 121 which is secured to the end surfaces 98 of the corner posts 28 (see FIG. 5C). The bottom joining panel 116 includes end surfaces 122 which are secured to the outwardly facing surfaces 100 of the bottom front rails 82. Slots can be provided in the top front rails 78 to receive the side joining panels 114. The connections may be made by welding, for example. The joining panel 110 is thus placed between the first and second containers 12, 14, with the front panels 102 (see FIGS. 6A to 6C) removed therefrom, and secured to the first and second containers 12, 14. The opening 118 is placed in communication with the inside area of the containers, forming the completed container having a through opening extending the entire length L of the completed container 10 (see FIG. 1). The bottom joining panel 116 extends in a plane similar to that of the bottom lip 94 such that the bottom surface of the inside area of the completed container is even throughout.

The joining apparatus 31 further includes rails 124, 126, which are used to secure the first and second container 12, 14 at the corner fittings 29. Bottom joining rails 124 extend downwardly from the bottom joining panel 106 and are secured to opposing bottom corner fittings 29. Top joining rails 126 are secured to the opposing upper corner fittings 29. The rails 124, 126 may be welded to the first and second containers 12, 14. Once the first and second containers 12, 14 are joined, the completed container 10 can be filled with cargo and shipped as desired.

Upon arrival at a shipping destination, the completed container 10 may be cut in order for separate use of the first and second containers 12, 14, according to their respective applications. The completed container is cut along junctions between the joining panel 110 and the top front rail 78, corner posts 28, and bottom front rail 82. Additionally, the completed container is cut along junctions between the bottom joining rails 124 and the bottom corner fittings 84, and along the junctions between the top joining panels 126 and the top corner fittings 84. Separation of the first and second containers 12, 14 occurs by processes known in the art. The joining panel 110 and the joining rails 124, 126 can then be thrown away or used for scrap.

The front panels 102 can be removed from the side panels 19 and secured to the front ends 27 of the first and second containers 12, 14 upon separation of the first and second containers 12, 14, as shown in FIGS. 6A to 6C. For example the tack welds described earlier, used to attach the front panels 102 to the side panels 21, can be grounded down to release the front panels 102 from the side panels 21. Or, front panels 102 attached to side panels 21 with hooks or lashing rings may be removed therefrom. The front panels 102 may then be secured to the front ends 27 of the first and second containers 12, 14, as shown in FIGS. 6A to 6C. The two separate containers 12, 14 may then be used for their respective applications.

With reference to FIG. 9, a flow chart of a process for use of the storage container is shown. In block 910, the front panels of the first and second containers are mounted to the inside area of the first and second containers, creating an opening into the inside area of the first and second containers at the front panels. In block 912, the first and second containers are joined together, forming the completed storage container. To accomplish this, the front panels are placed adjacent to one another with their respective openings in communication with one another, forming the completed storage container. In block 916, the completed container is loaded with cargo in the inside area of the completed container. In block 918, the completed storage container is shipped with the cargo loaded therein. In block 920, the cargo is unloaded from the container upon arrival at a destination. In block 922, the completed container is separated into the first and second containers. In block 924, the front panels are removed from the inside area. In block 926, the front panels are mounted onto the fronts of the first and second containers.

The present invention may be used according to an advantageous financing model. The completed container 10 may be formed at a shipping origin. The completed container 10 may be used to ship cargo across seas from the shipping origin to a shipping destination. The completed container 10 may be rented to a shipping company, which uses the container for the shipping of cargo from the shipping origin to the shipping destination. The storage container may be sold to a third party, preferably at the shipping destination, for use in shipping across sea or land, or sold as a container for the storage of goods, as described above. In this manner, the manufacturer or seller of storage containers can transfer containers from a shipping origin to a shipping destination without having to pay the shipping costs associated with shipping the containers as cargo. One way rental of the completed container also precludes the necessity of having to pay the costs associated with the return of the completed container 10, or any portion thereof, to the shipping origin.

Although this invention has been described in certain specific embodiments, many additional modifications and variations would be apparent to those skilled in the art. For example, the forklift pockets 20 and the tunnel 32 can have other configurations and structure. The bearing members 49 can be a single plate or several members of various shape for receiving the load of a fork of a forklift.

It is therefore to be understood that this invention may be practiced otherwise than as specifically described. Thus, the present embodiments of the invention should be considered in all respects as illustrative and not restrictive, the scope of the invention to be determined by any claims supportable by this application and the claims' equivalents. 

1. A storage container comprising: a first container portion having a first length, and having a first front portion; and a second container portion having a second length, and having a second front portion wherein the first length is longer than the second length; wherein the first and second front portions are coupled to form a cargo container approximately 40 feet in length and having a opening extending approximately 40 feet through the storage container, and wherein a first panel to cover the first end portion is mounted to the storage container and a second panel to cover the second end portion is mounted to the storage container.
 2. The storage container of claim 1 wherein the first container portion is approximately 24 feet in length and the second container portion is approximately 16 feet in length.
 3. The storage container of claim 1, wherein the first and second front portions are coupled by a joining panel.
 4. The storage container of claim 3, wherein the first and second container portions and the joining panel enclose an inner area of the storage container.
 5. The storage container of claim 4, wherein a bottom portion of the joining panel is aligned with a bottom inside surface of the first and second container portions to form an even surface.
 6. The storage container of claim 3, wherein the first and second front portions are further coupled by rails.
 7. The storage container of claim 6, wherein the rails are at least partially secured to corner fittings of the first and second container portions.
 8. The storage container of claim 1, wherein the first and second panels are mounted to an inside surface of the storage container.
 9. A storage container comprising: forklift pockets extending laterally near a bottom surface of the storage container; a tunnel extending along a portion of a length of the bottom surface of the storage container from a first end of the storage container; the tunnel being defined by two spaced-apart side members extending perpendicular to the fork pockets; and at least one opening in at least one of the two spaced-apart side members of the tunnel at an intersection of at least one forklift pocket and the tunnel, the opening configured to allow passage of a fork of a forklift from the forklift pocket into the tunnel.
 10. The storage container of claim 9, wherein the forklift pocket is defined by a top plate, a bottom plate, and cross members extending laterally across the bottom surface of the storage container.
 11. The storage container of claim 10, wherein the at least one forklift pocket extends from a side opening in a bottom side rail of the container to the at least one opening in the two side members.
 12. The storage container of claim 11, wherein the top plate of the at least one forklift pocket is secured to a container flooring.
 13. The storage container of claim 12, wherein the container flooring and a lateral member of the tunnel are aligned to form an even flooring surface in an inside area of the container.
 14. A method of shipping a container, comprising: fixing a first container and a second container together, the first container measuring approximately 24 feet in length and the second container measuring approximately 16 feet in length, to form a completed container measuring approximately 40 feet in length; mounting front panels of the first and second containers to the completed container such that a through opening of approximately 40 feet in length extends through the completed container; loading the completed container; shipping the completed container; and unloading the completed container.
 15. The method of claim 14, wherein the first container and second container are welded together by welding the first and second containers to a joining panel.
 16. The method of claim 15, wherein the first container and second container are further welded together by welding the first and second containers to at least one joining rail.
 17. The method of claim 14, further comprising separating the first container and the second container.
 18. The method of claim 17, further comprising: removing the front panels from the inside surface of the container; and mounting the front panels on front portions of the first container and the second container.
 19. The method of claim 14, further comprising renting the completed container measuring approximately 40 feet in length for shipping a load.
 20. The method of claim 19, further comprising selling the first and second containers to one or more parties and delivering the first and second containers to the one or more parties after shipping the completed container. 